DryBottomAshHandlingOptions&NewTechnology

WorldofCoalAshConference2009

2009 World of Coal Ash (WOCA) Conference - May 4-7, 2009 in Lexington, KY, USA http://ww.flyash.info/

EliminationofFlyAshfromAshPondsOptions&Advantagesp g

VacuumSystemtoSiloN h d i i ti i t k Nochangesunderprecip,usesexistingintakes

Limitonconveyingcapacityvs.distance

Dilute Pressure System to SiloDilutePressureSystemtoSilo MostPressureSystemsareDry

V /P T f S t t Sil Vacuum/PressureTransferSystemtoSilo Useexistingashintakes Nolimitonconveyingcapacityanddistance

DensePressuretoSilo Canreplacevacuumsystem Limitonconveyingcapacityanddistance

DryFlyAshConveyingDilute/DenseFlowRegimesg

DryFlyAshConveyingCapacityvs.Distancep y

DryFlyAshConveyingVacuumSystemtoSiloy

DryFlyAshConveyingPressureSystem MostAlreadyDryy y y

DryFlyAshConveyingVacuum/PressureTransferStation

DryFlyAshConveyingVacuum/PressureTransferStation

DryFlyAshConveyingEnclosedVacuum/PressureTransferStation

DryFlyAshConveyingVacuum/PressureTransferSilo

DryFlyAshConveyingVacuum/PressureTransferSiloInstallation

DryFlyAshConveyingPressureFeedersUnderTransferSilo

DryFlyAshConveyingPressureFeedersUnderTransferSilo

DryFlyAshConveyingPressureLinetoRemoteSilo

DryFlyAshDensePhasePressure CanReplaceVacuumSystemp y

15

DryBottomAshConveying

1940s1950s:UCCdevelopsdrybottomashconveying

withNUVEYOR pneumaticashconveyingsystems,gravitydischargeashpitg y g phoppers.

RenditionofaUCCNUVEYORsystemforautilityboiler,includinggravitydischargeashpithopper.

DryBottomAshConveyingTemperaturep

DryBottomAshConveyingSlagFallsg

EliminationofBottomAshfromAshPondsOptions&Advantagesp g

ReCirculatingWaterSystem No changes under boiler uses existing hopper Nochangesunderboiler,usesexistinghopper Switchtonewsystemin3dayoutage

SubmergedFlightConveyor SFCg g y Mosteconomicalchoice Simplesolutionifspaceisavailable

i C i DryHopperPneumaticConveying PAX Nowater,returnsheatbacktoboiler Easiest100%dryoptiontogetoutofboilerbuilding

VibratoryConveying VAX Nowater,returnsthemostheatbacktoboiler Continuousremovalofbottomash

DryBottomAsh ReCirculationSystem

DryBottomAsh ReCirculationSystem

DryBottomAsh SFC

DryBottomAsh SFC

DryBottomAsh SFC

DryBottomAsh PAXSystem

DryBottomAsh PAXSystem

DryBottomAsh VAX

DryBottomAsh VAX

DryBottomAsh VAX

DryBottomAshFeaturesComparisonp

ReCircTanks SFC PAX VAX

CostsDesignandmaterialCosts $5M $2M $3.5M $3.5M

CostsInstallationCost $4.5M $1.5M $3.5M $2.5M

PreOutageConstruction6 months 2 months 2 months 2 months

OutageRequirement

Duration6months 2months 2months 2months

OutageConstruction 3days 3weeks 8weeks 6weeks

OutageStartUp 2 3days 1 2days 3 4days 1 2days

LeadTime 9months 9months 12months 12months

DryBottomAshFeaturesComparisonp

Re Circ Tanks SFC PAX VAXReCircTanks SFC PAX VAX

YardPipingCorridor Yes No Yes No

Boiler&YardSpaceBoilerHouseExitCorridorforMechanicalConveyor

No Yes No Yes

YardFootPrint 6500sqft 1500sqft 1500sqft 1000sqft

Storage Bin Serves moreMultipleUnitsynergies

StorageBinServesmorethanoneboiler

Yes No Yes No

DryBottomAshFeaturesComparisonp

RecircTanks SFC PAX VAX

HighPressurePumps Yes No No No

Vacuum/PressureBlowers

No No Yes No

O ti d M i t

Refractory Yes existingUsuallynone

YesUsuallynone

Yes OperationsandMaintenanceCosts

ConveyorChainReplacement

No Yes NoYes

SecondaryConveyor

CrushersYes existing

(3)Usuallynone

Yes(3) Yes(1)

ConveyingConveyingpipeline/valves

Yes No Yes No

DryBottomAshFeaturesComparison

Re Circ Tanks SFC PAX VAX

p

ReCircTanks SFC PAX VAX

Makeupwater 100gpm 50gpm None None

Cooling Water 400 gpm 400 gpm None NoneWaterConsumption

CoolingWater 400gpm 400gpm None None

ConveyingWater(recirculating)

2500gpm None None None

Power Consumption

Pumps 600HP 50HP None None

Blowers/Fans None None 200 HP 50 HPPowerConsumption Blowers/Fans None None 200HP 50HP

MechanicalDrives 50HP 100HP 50HP 75HP

DryBottomAshDecisionAnalysis

Technology AlternativesTechnology Alternatives

1 = Worst, 5 = Best Scale 1-5 Re-Circ System SFC PAX VAX

Criteria for Determing Technology Selection WT SC Total SC Total SC Total SC Total

Water Usage/Availability 0 2 0 3 0 5 0 5 0Outage Time Available 0 5 0 4 0 2 0 3 0Total Installed Cost 0 1 0 5 0 3 0 3 0Total Installed Cost 0 1 0 5 0 3 0 3 0Operation & Maintenance Cost 0 2 0 5 0 3 0 4 0Power Consumption 0 1 0 4 0 2 0 5 0Boiler House Corridor Availability 0 5 0 3 0 5 0 3 0Boiler House Corridor Availability 0 5 0 3 0 5 0 3 0Multiple Unit Synergies 0 5 0 2 0 4 0 2 0

Weighted Total Score 0 0 0 0

DecisionAnalysisFavorsReCirculationSystem

Technology AlternativesTechnology Alternatives

1 = Worst, 5 = Best Scale 1-5 Re-Circ System SFC PAX VAX

Criteria for Determing Technology Selection WT SCTotal SCTotal SCTotal SC Totalg gy

Water Usage/Availability 2 2 4 3 6 5 10 5 10Outage Time Available 5 5 25 4 20 2 10 3 15Total Installed CostTotal Installed Cost 2 1 2 5 10 3 6 3 6Operation & Maintenance Cost 2 2 4 5 10 3 6 4 8Power Consumption 2 1 2 4 8 2 4 5 10Boiler House Corridor Availability 5 5 25 3 15 5 25 3 15Boiler House Corridor Availability 5 5 25 3 15 5 25 3 15Multiple Unit Synergies 5 5 25 2 10 4 20 2 10

Weighted Total Score 87 79 81 74

DecisionAnalysisFavorsSFCSystem

Technology AlternativesTechnology Alternatives

1 = Worst, 5 = Best Scale 1-5 Re-Circ System SFC PAX VAX

Criteria for Determing Technology Selection WT SCTotal SCTotal SCTotal SC Total

Water Usage/Availability 4 2 8 3 12 5 20 5 20Outage Time Available 5 5 25 4 20 2 10 3 15Total Installed CostTotal Installed Cost 4 1 4 5 20 3 12 3 12Operation & Maintenance Cost 3 2 6 5 15 3 9 4 12Power Consumption 2 1 2 4 8 2 4 5 10Boiler Ho se Corridor A ailabilitBoiler House Corridor Availability 1 5 5 3 3 5 5 3 3Multiple Unit Synergies 1 5 5 2 2 4 4 2 2

Weighted Total Score 55 80 64 74

DecisionAnalysisFavorsPAXSystem

Technology AlternativesTechnology Alternatives

1 = Worst, 5 = Best Scale 1-5 Re-Circ System SFC PAX VAX

Criteria for Determing Technology Selection WT SCTotal SCTotal SCTotal SC Totalg gy

Water Usage/Availability 5 2 10 3 15 5 25 5 25Outage Time Available 1 5 5 4 4 2 2 3 3T t l I t ll d C tTotal Installed Cost 3 1 3 5 15 3 9 3 9Operation & Maintenance Cost 3 2 6 5 15 3 9 4 12Power Consumption 3 1 3 4 12 2 6 5 15Boiler House Corridor Availability 5 5 25 3 15 5 25 3 15Multiple Unit Synergies 5 5 25 2 10 4 20 2 10

Weighted Total Score 77 86 96 89

DecisionAnalysisFavorsVAXSystem

T h l Alt tiTechnology Alternatives

1 = Worst, 5 = Best Scale 1-5 Re-Circ System SFC PAX VAX

Criteria for Determing Technology Selection WT SCTotal SCTotal SCTotal SC TotalCriteria for Determing Technology Selection WT SCTotal SCTotal SCTotal SC Total

Water Usage/Availability 5 2 10 3 15 5 25 5 25Outage Time Available 1 5 5 4 4 2 2 3 3Total Installed Cost 3 1 3 5 15 3 9 3 9Operation & Maintenance Cost 3 2 6 5 15 3 9 4 12Power Consumption 5 1 5 4 20 2 10 5 25Boiler House Corridor Availability 2 5 10 3 6 5 10 3 6Multiple Unit Synergies 1 5 5 2 2 4 4 2 2

Weighted Total Score 44 77 69 82

PreAssemblyOptions

PreAssemblyOptions

PreAssemblyOptions

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